Method for cooking a pizza

ABSTRACT

A cooking apparatus and method is provided which includes a rotatable food support member for supporting a food item thereon. A drive mechanism is connected to the food support member for rotating the food support member. The cooking apparatus further includes upper and lower housings disposed above and beneath a portion of the food support member. The upper and lower housings include an upper and lower heating member respectively with each of the upper and lower heating members providing a heat output which varies from a first end adjacent to an outer edge of the food support member to a second end adjacent to an inner center portion of the food support member, wherein the heat output is greater at the first end than at the second end. The drive mechanism rotates the food support member with the upper and lower heating members applying heat to the food support member to cook the food item contained thereon. Preferably, the food support member includes a solid base portion for supporting the food item.

This application is a divisional of application Ser. No. 09/267,981,filed Mar. 12, 1999 now U.S. Pat. No. 6,125,740 which application(s) areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to the field of electric ovens and moreparticularly to a rotatable cooking apparatus for cooking food itemssuch as a pizza.

2. Description of the Art

In the field of food preparation and particularly cooking of pizzas, itis well known to utilize a conventional electric oven. However, severalcommon problems are associated with using a conventional oven such ashaving to wait to preheat the oven to begin cooking and uneven cookingof the pizza in the oven. For example, a conventional oven often has hotspots where heat is concentrated in a particular area of the oven andthis leads to overcooking a portion of the pizza adjacent the hot spotwhile other portions of the pizza may not be fully cooked. Often it isdifficult to ensure that the crust of the pizza is fully cooked withoutovercooking the top of the pizza. Additionally, cooking the pizza oftenresults in drippings of toppings and other ingredients which fall ontothe surfaces of the oven.

In view of the problems associated with using a conventional oven tocook a pizza, it is known in the field of electric ovens to have anelectric oven specifically designed for use in cooking pizzas or othersimilar types of foods. For example, U.S. Pat. No. 5,496,987 is directedto an electric oven particularly designed for cooking pizzas. In such adevice, the oven includes heating coils which are supported above a baseportion of the oven so that an entire pizza can be positioned betweenthe coils for cooking the pizza. One problem with such a device is thatsince the heating coils extend over the entire portion of the pizza, thesize or “footprint” of the oven is relatively large and is not efficientfor use or storage by a consumer in a kitchen environment, for exampleon a kitchen counter.

U.S. Pat. No. 5,586,488 discloses a portable pizza oven which includes afixed upper and lower casing having an upper heater assembly and a lowerheater assembly located within the casings. A pan is insertable into thecooking chamber so that the entire pizza is disposed between the upperand lower heater assemblies to cook the pizza. Again the size of thedevice is cumbersome or inefficient for a consumer as the upper andlower casings containing the heater assembly are sized so that an entirepizza can fit within the upper and lower casing.

What is needed is an apparatus which provides for fast efficient cookingof a food item such as a pizza and which is convenient and efficient ina kitchen environment by having a relatively small footprint for easyuse and storage. What is further needed is an apparatus for cooking apizza or other food item in which the application of heat to the fooditem is applied in such a way to allow even cooking of the food itemthroughout the entire food item.

SUMMARY OF THE INVENTION

The present invention is directed to a cooking apparatus which allowsfor fast, efficient cooking of a food item such as a pizza whileproviding proportionate heating throughout the entire pizza to ensurethat the entire pizza is cooked evenly and completely. The presentinvention further provides a cooking apparatus which has a smallfootprint for efficient use and storage by a consumer in a kitchenenvironment.

According to one aspect of the present invention, a cooking apparatus isprovided which includes a rotatable food support member for retaining afood item thereon. A drive mechanism is connected to the food supportmember for rotating the food support member. The cooking apparatusfurther includes upper and lower housings disposed above and beneath thefood support member. The upper and lower housings include an upper andlower heating member respectively with each of the upper and lowerheating members providing a heat output which varies from a first endadjacent to an outer edge of the food support member to a second endadjacent to an inner center portion of the food support member. The heatoutput is greater at the first end than at the second end. The drivemechanism rotates the food support member with the upper and lowerheating members applying heat to the food support member to cook thefood item.

In one embodiment, the upper and lower housings define a substantiallypie-shaped portion having a front end and diverging sides so as to covera pie-shaped sector of the food support member. Preferably, thesubstantially pie-shaped portion of the food support member covered bythe upper and lower housings is equal to or less than about one-quarterof the total area of the food support member. Preferably, the upper andlower heating members each provide a heat output which varies from afirst end adjacent to an outer edge of the food support member to asecond end adjacent to an inner center portion of the food supportmember so that the heat output is greater at the first end than at thesecond end. In such an embodiment, the drive mechanism rotates the foodsupport member with the upper and lower heating members applying heat toa pie-shaped sector of the pizza or other food item carried by the foodsupport member to cook the food item.

According to another aspect of the present invention, the rotatable foodsupport member preferably comprises a solid base portion for supportingthe food item such as a pizza. Preferably, the surface of the solid baseportion of the food support member includes a series of interruptions inthe surface such as a waffle pattern such that air pockets are createdtherein to assist in the browning of the crust of the pizza. Preferably,the food support member includes a downwardly extending annular rimwhich assists in retaining heat under the solid base portion of the foodsupport member.

Pursuant to another aspect of the present invention, the upper and lowerheating members preferably comprise metal sheathed heating elements andare arranged in a substantially pie-shaped orientation such that agreater portion of the heating elements are disposed toward the outeredge of the heating members than toward the front end of heating membersadjacent the center of the food support member. Preferably, the upperand lower heating members are enclosed by an outer wall such that theheat is directed toward the food support member. In one embodiment, theannular rim of the food support member is disposed adjacent an outeredge portion of the outer wall of the lower heating member such that theheating element of the lower heating member is substantially enclosedbetween the food support member and the outer wall of the lower heatingmember.

The above-described features and advantages, along with various otheradvantages and features of novelty, are pointed out with particularityin the claims of the present application which form a part hereof.However, for a better understanding of the invention, its advantages,and objects obtained by its use, reference should be made to thedrawings which form a further part of the present application and to theaccompanying descriptive matter in which there is illustrated anddescribed preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view of one preferred embodiment of arotatable cooking apparatus according to the principles of the presentinvention;

FIG. 2 is a partial sectional top plan view of the cooking apparatus asshown in FIG. 1;

FIG. 3 is sectional bottom view of an upper portion of the cookingapparatus as shown in FIG. 1;

FIG. 4 is a perspective view of the cooking apparatus shown in FIG. 1without the food support member:

FIG. 5 is a perspective view of the cooking apparatus shown in FIG. 1;

FIG. 6 is a top plan view of the food support member of the cookingapparatus shown in FIG. 1;

FIG. 7 is a top plan view of a heating member for a first alternativeembodiment of a cooking apparatus according to the principles of thepresent invention;

FIG. 8 is a side sectional view of a second alternative embodiment of acooking apparatus according to the principles of the present invention;

FIG. 9 is a top sectional view of a portion of the cooking apparatusshown in FIG. 8;

FIG. 10A is an electrical schematic diagram of one embodiment ofelectrical circuitry for use in a cooking apparatus according to theprinciples of the present invention; and

FIG. 10B is an electrical schematic diagram of a second alternativeembodiment of electrical circuitry for use in a cooking apparatusaccording to the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings in which similar elements are numberedidentically throughout, a description of the preferred embodiments isprovided. In FIG. 1, a side sectional view of a cooking apparatusaccording to the principles of the present invention is generallyillustrated at 10. The cooking apparatus generally includes a baseportion 12 and a lower housing 20 and an upper housing 50 extendingforward from the base portion 12. The lower housing 20 includes a baseor shell portion 22 and includes a substantially pie-shaped heatingmember 24. Preferably, an outer wall or rim 26 encloses heating member24. In this way, heat generated by the heating member 24 is generallydirected upward toward a portion of a moveable food support member 70.The lower housing 20 includes a rotatable shaft 28 which is sized forengagement with a corresponding shaft 72 of the food support member 70.In one embodiment, the lower housing 20 includes side extensions 21which provide additional support for the lower housing as well asproviding additional spacing between the heating member 24 and objectsadjacent the apparatus.

The base or shell portion 22 of the lower housing 20 preferably includesair intake apertures 23 which help assist in air circulation throughoutthe cooking apparatus to cool the apparatus. In one embodiment, aclearance or gap 27 is provided between the base portion 22 and a topportion of the lower housing 20 to allow for improved air flow.Similarly, the upper housing 50 preferably has a clearance or gap 55 toallow for improved air flow.

The cooking apparatus 10 includes a drive mechanism 30 for rotation ofthe food support member 70 which is disposed between the upper and lowerhousings 20, 50. In one embodiment, the drive mechanism 30 includes anelectric motor 32 which is connected to a shaft 38 and correspondingworm gear 36 to gear 34 which is connected to the rotatable shaft 28. Inthis way, the electric motor rotates the food support member 70 which isconnected to the rotatable shaft 28. In a preferred embodiment, thedrive mechanism 30 is designed to rotate the food support member 70 atapproximately ½ to 2 RPMs and more particularly at 1 RPM. It isappreciated that other drive linkages may be utilized in connecting therotational output of the electric motor 32 with the food support member70. Additionally, the speed of rotation of the food support member maybe varied to accommodate different cooking conditions.

It is appreciated that the cooking apparatus may be utilized to cook avariety of food items. For example, the cooking apparatus may be used tocook frozen pizzas, as well as hot hors d'oeuvres or sandwiches. In thefollowing description of preferred embodiments, the cooking apparatus 10will be described in the context of cooking a frozen pizza as aparticular example of the present invention. Accordingly, the foodsupport member 70 will be referred to as the pizza support member.

In one embodiment, the drive mechanism 30 preferably includes a fan 40connected to the electric motor 32. This way, the fan blades draw air inthrough the air intake apertures 23 and the clearance gap 27 in thelower housing 20 and circulate the air to force the air out throughcorresponding apertures 54 and clearance gap 55 in the upper housing 50.The fan 40 thus provides for cooling of the pizza cooking apparatus 10while still allowing for rapid cooking of the pizza on the pizza supportmember 70.

The upper housing 50 extends forward from the base 12 of the pizzacooking apparatus 10 at a position above the lower housing 20. The upperhousing 50 is preferably positioned at approximately the same radialposition as the lower housing 20. The upper housing 50 includes a baseor shell portion 52 with a pie-shaped heating member 56 disposed at alower bottom portion of the upper housing 50 facing the pizza supportmember 70. Preferably, an outer wall or rim 58 surrounds the heatingmember 56 so that heat generated from the heating member 56 is directeddownward toward the pizza support member 70 which is disposed forrotation between the upper and lower housings 50, 20.

The upper and lower housings 50, 20, and the upper and lower heatingmembers 56, 24 cover a pie-shaped section of pizza support member 70.The remaining portion of pizza support member 70 is outside of the upperand lower housings and the heating members. In use, a pizza disposed onrotating support member 70 is rotated relative to sections of the pizzapassing between upper and lower housings 50, 20 to be heated by upperand lower heating members 56, 24.

Preferably, the upper housing 50 is disposed at a slight upward angle toassist in placement and removal of the pizza on the pizza support member70, and also the pizza support member 70 on the lower housing 20. In oneembodiment, the upper housing 50 is disposed at a 10 degree upward anglewith respect to the horizontal axis.

The pizza support member 70 is preferably sized to support a round pizzathereon (the pizza 2 is shown in dashed lines in FIG. 1 disposed on thepizza support member 70). In one embodiment, the pizza support member isdesigned to support a 12 inch pizza which is a typical size for a frozenpizza. The pizza support member 70 includes a base member 71 with acentral shaft or rod 72 extending down from the center of the pizzasupport member 70 for engagement with the rotatable shaft 28 extendingupward from the lower housing 20. It is appreciated that a variety ofconnections may be utilized between the pizza support member 70 and therotatable shaft 28 of the drive mechanism 30. In this way, the electricmotor 32 of drive mechanism 30 is able to rotate the pizza supportmember about a central axis so that the base 71 of the pizza supportmember 70 rotates between the upper and lower heating members 24, 56 ofthe upper and lower housings 50, 20.

In a preferred embodiment, a base portion 71 of the pizza support member70 is preferably constructed of a solid material, preferably metal. Inthis way, as the pizza is cooked on the pizza support member 70, anydrippings from the pizza such as oils or cheese are retained on thesolid base 71 of the pizza support member. Preferably, the outer edge ofthe base 71 of the pizza support member includes a raised edge portion73 so that any drippings from the pizza are contained within the pizzasupport member 70. This allows for easier cleaning of the lower housing20 and the countertop, and also increases the safety of the pizzacooking apparatus by reducing the chance of drippings from the pizzafalling within the lower heating member 24 of the lower housing 20. In apreferred embodiment, the pizza support member 70 further includes anouter annular rim 76 which extends downward from the base 71 of thepizza support member 70. This annular rim 76 helps stiffen the pizzasupport member 70 to help keep it from warping during heating andfurther serves to help retain heat within the base 71 of the pizzasupport member 70. It is appreciated that other designs for the pizzasupport member 70 may be utilized such as an open grill type structure.

In a preferred embodiment, the solid base portion 71 of the pizzasupport member 70 includes a patterned surface 74 for contact with thecrust of the pizza to cook thereon. In one embodiment as shown in FIG.6, the solid base portion of the pizza support member 70 includes awaffle pattern with interruptions in the surface of the base 71. In thisway, various air pockets are formed within the base 71 of the pizzasupport member 70 during cooking which allows the pizza cookingapparatus 10 to brown the crust of the pizza in an even manner. It isappreciated that other types of patterns may be utilized to provideinterruptions in the base 71 of the pizza support member 70 toaccomplish this result.

The pizza cooking apparatus 10 preferably includes a control panel 60having control circuitry for use in controlling operation of the pizzacooking apparatus. In one embodiment as shown in FIG. 1, the controlpanel 60 is located on an upper portion of the base 12 of the pizzacooking apparatus for easy access by a user. The control panel 60 mayinclude switches and a timer for turning on the heating members 24, 56of the upper and lower housings 50, 20 for cooking the pizza. Thecontrol panel 60 further controls the operation of the electric motor 32of the drive mechanism 30 to rotate the pizza support member 70 and tooperate the fan 40 to cool the outer surfaces of the pizza cookingapparatus. It is contemplated that the control panel 60 may includecontrol circuitry to allow a user to vary the operation of the heatingmembers of the upper and lower housings 50, 20 to customize the heatapplied to the pizza. For example, if a user desires to cook the pizzaso that the crust is cooked more than the top of the pizza, the controlpanel 60 could allow the user to turn down or off the upper heatingmember 56 while still providing heat through the lower heating member 24to further cook the crust of the pizza disposed on the pizza supportmember 70. In the embodiment shown in FIG. 10A, the control circuitryincludes a timer 62 and a three position double pole slide switch 64 toallow the user to operate the upper and lower heating membersindependent from each other. As another example, the control panel 60could be used to vary the wattage of the heating members so that theuser could increase or decrease the amount of heat being supplied byeither the upper or lower heating members. In the embodiment shown inFIG. 10B, the control circuitry includes a timer 62 and an adjustablephase control circuit 66 for the upper and lower heating members to varythe intensity of the heating members. It is further contemplated that atimer 62 may be utilized with the control panel 60 so that the user canset the timer for a predetermined time period and then the pizza cookingapparatus is activated to cook the pizza through the lower and upperheating members 24, 56 while rotating the pizza support member 70. Afterthe predetermined time, the pizza cooking apparatus would then turnitself off and the pizza would be fully cooked and ready to eat by theuser. It is appreciated that variations may be utilized in the controlpanel to provide a variety of cooking options for the user. It isfurther noted that the location of the control panel may be varied aslong as it provides easy access for the user.

Turning now to the operation of the pizza cooking apparatus 10 forcooking a pizza, the user places the pizza support member 70 on thelower housing 20 through the connection of the shaft or rod 72 and therotatable shaft 28 extending up from the lower housing 20. It isappreciated that the pizza support member 70 may be preassembled, andpermanently affixed if desired. The user then places a pizza on thepizza support member 70. The pizza support member may be sized to fit aparticular size of pizza. In the preferred embodiment, the pizza supportmember is sized to fit a standard 12 inch frozen pizza on the uppersurface of the pizza support member. The user then utilizes the controlpanel 60 which may include an ON/OFF switch and preferably may include atimer for cooking of the pizza. The pizza cooking apparatus 10 is turnedon at which time the electric motor 32 of the drive mechanism 30 beginsto rotate the pizza support member 70 and the pizza contained thereonthrough the heating members 56, 24 of the upper and lower housings 50,20.

The heating members 24, 56 contained within the lower and upper housingsare activated to begin providing heat. In the preferred embodiment, theupper and lower heating members 24, 56 constitute sheathed metal heatingelements 25, 57. The heating members 24, 56 begin to heat up and applyheat to begin to cook the pizza rotating through upper and lower heatingmembers. As shown in FIGS. 2 and 3, the upper and lower heating members56, 24 are positioned within a pie-shaped portion of the upper and lowerhousings 50, 20 such that a greater portion of the heating elements 25,57 of the heating members 24, 56 are disposed adjacent the outer edge ofthe pizza support member 70. In this way, the upper and lower heatingmembers 56, 24 supply a greater output of heat to the outer portion ofthe pizza support member 70 and consequently the pizza contained thereonsince as the pizza rotates, the center portion of the pizza remainsadjacent to the heat supplied by the heating members while the outeredge portion of the pizza rotates in and out of the heat supplied by theupper and lower heating members. In this way, the positioning of theheating elements in a pie-shaped orientation allows for application ofvaried heating throughout a pie-shaped (or radius) section of the pizzaso that the entire pizza is cooked evenly and proportionately. It isappreciated that numerous variations in the shaping of the heatingelements 25, 57 of the heating members 24, 56 can be utilized whilestill providing for variable heat output between the center and the edgeof the pizza so that the heating members apply greater heat outputtoward the outer edge of the pizza support member 70 than is supplied inthe center portion of the pizza support member.

As the pizza support member rotates the pizza between the lower andupper heating members 24, 56 of the housings, the waffle pattern 74 ofthe solid base 71 of the pizza support member 70 allows for evenbrowning of the pizza crust as the pizza cooks. In this way, the pizzacooking apparatus cooks the pizza in such a way that the entire pizza iscooked evenly with the crust being sufficiently cooked as the top of thepizza cooks. Additionally, it should be noted that the present inventionallows for easy visual inspection of the pizza during cooking as thepizza contained on the pizza support member is rotating within view ofthe user.

Preferably, during use, the electric motor 32 of the drive mechanism 30also drives a fan 40 within the base 12 of the pizza cooking apparatus10. In this way, air is circulated from apertures 23 and clearance gap27 within the lower housing 20 through the base portion 12 of the pizzacooking apparatus and out through apertures 54 and clearance gap 55 inthe upper housing 50. Circulation of air by the fan 40 allows forcooling of the pizza cooking apparatus to prevent a user from burningthemselves by touching of the outer surfaces of the pizza cookingapparatus during use. It is appreciated that the number of apertures anddirection of air flow may be varied while still providing for adequatecooling of the outer surfaces of the pizza cooking apparatus.

It is further noted that preferably the outer annular rim 76 of thepizza support member 70 is disposed adjacent the outer wall or rim 26 ofthe lower housing 20. In this way, the pizza support member 70 and theouter wall 26 of the lower housing 20 cooperate to form a substantiallyclosed chamber for the lower heating member 24 which increases theefficiency of the pizza cooking apparatus. This also serves to preventaccess to the heating member 24 contained in the lower housing 20. Thishelps prevent access by a user and further prevents food particles ordrippings from falling or migrating into the heating member 24 of thelower housing 20.

When the pizza is fully cooked, the user then stops rotation of thepizza support member 70 through the control panel 60 (or the apparatusmay automatically stop cooking pursuant to a timer mechanism) andremoves the pizza from the pizza support member to consume the pizza.Alternatively, the user may remove the pizza support member containingthe pizza and use the pizza support member 70 as a serving tray. At thistime, the heating members 24, 56 of the lower and upper housings areturned off.

In operation, the cooking apparatus of the present invention providesfor fast, efficient and even cooking of a pizza. For example, a 12 inchfrozen pizza may be cooked in approximately 12 minutes using oneembodiment of the pizza cooking apparatus 10. Additionally, the sizingof the lower and upper heating members 24, 56 to cover only a pie-shapedportion of the pizza support member 70 allows for a relatively smallsize or footprint of the pizza cooking apparatus so that the pizzacooking apparatus may be easily stored on a counter in a kitchen. Forstorage, the pizza support member 70 may be removed and storedseparately from the rest of the cooking apparatus. In a preferredembodiment, the upper and lower housings 50, 20 each include apie-shaped portion which is less than or equal to about one-quarter ofthe total surface area of the pizza support member 70. The illustratedembodiment is about one-sixth of the total surface area. Otherembodiments, up to one-half of the pizza support member surface area maybe advantageously employed.

While one embodiment of the present invention discloses a sheathedheating elements 25, 57 to provide the heat for cooking a pizza, it isappreciated that a variety of other heating elements may be utilized inaccordance with the principles of the present invention. For example,referring to FIG. 7, an alternative heating member is provided. In FIG.7, the lower heating member 124 of the lower housing 120 includes a baseportion 126 wherein a resistance wire 128 is wrapped around the base 126of the lower heating member 124. The base portion 126 is preferablyprovided in a pie-shaped portion and the spacing between the resistancewire 128 disposed around the base portion may be varied to vary the heatoutput of the heating member 124. For example, as shown in FIG. 7, thespacing between the resistance wire 128 may be greater near the frontend of the assembly with the spacing decreasing toward the outer edge ofthe heating member. In this way, less heat is applied toward the frontend of the heating member 124 and consequently greater heat outputtoward the outer edge of the heating member. This variation of the heatoutput provides for even cooking of the pizza which is rotating on thepizza support member 70 above the heating member 124. A similar typeheating member would be used for the upper heating member as well. Insuch an embodiment, it is preferable to have some type of screen orglass cover over the heating member 124 of the lower housing so that nodrippings, crumbs or toppings from the pizza may gain access to theheating member 124 containing the live resistance wire 128.

Referring to FIG. 8, a second alternative embodiment for the heatingmember is disclosed. In this embodiment, the heating member 224 includesa quartz tube 226 disposed within the lower housing 220 to apply heat tothe pizza support member. Referring to FIG. 9, deflector shields 228 areapplied to provide a varied heat output. The deflector shields aredisposed to form a pie-shaped heating section so that the quartz tube226 applies heat in a substantially pie-shaped pattern to the pizzasupport member. This allows for even heating of the pizza rotating onthe pizza support member. Preferably, a screen or glass shield would bedisposed between the pizza support member and the quartz tube 226 toprevent any access to the quartz tube heating element by the user and toprevent any drippings or crumbs from the pizza being cooked fromreaching the quartz tube. Alternatively, the quartz tube could have anopaque material applied to the quartz tube to vary the heat output alongthe length of the quartz tube.

It is to be understood that even though numerous characteristics andadvantages of various embodiments of the present invention have been setforth in the foregoing description, together with the details of thestructure and function of various embodiments of the invention, thisdisclosure is illustrative only and changes may be made in the details,especially in matters of shape, size, and arrangement in part within theprinciples of the present invention, to the full extent indicated by thebroad general meaning of the terms in which the appended claims areexpressed. All alternative modifications and variations of the presentinvention which fall within the spirit and broad scope of the appendedclaims are covered.

1. A method for cooking a pizza comprising the steps of: placing a pizza on a generally circular, rotatable food support member having a central axis of rotation wherein the food support member is adapted to be disposed in a substantially horizontal orientation and the pizza is positioned over the axis of rotation of the food support member; and rotating the pizza contained on the food support member multiple times through a heating chamber defined by upper and lower housings, the housings covering only a portion of the food support member such that heating members in the housings apply heat to only a portion of the pizza as it rotates through the heating chamber to cook the pizza.
 2. The method of claim 1 further comprising the step of removing the food support member from the heating chamber after the pizza is cooked. 